May
1981
FORM:
QM-866A
MODEL
MIC-2
0QPY
gETU1~
TO
~QLO~
OWN
ER’S
MANUAL
MILLER
ELECTRIC
MFG.
CO.
718S
BOUNDSST
P0
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
30
CENTS
fuMIER
NINSA
CODE
NO.
4579
PRINTED
IN
U.S.A.
J~
~
LIMITED
WARRANTY
EFFECTIVE
JUNE
1
1979
S
Th
s
wa
anty
supe
sedes
dli
previous
MILLER
wa
an es
and
S
ex
clus
yew
h
noothe
guarantees
or
warrant
es
exp
essed
o
mp
led
5
LIMITED
WARRANTY~Subject to
the
terms
and
conditions
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
submitted
by
the
original
user
within
the foregoing
periods.
to
its
Distributor/Dealer that
all
new
and unused
Equipment
furnished by
Miller
is free from defect
in
workmanship
and
In
the
case
of
Miller’s breach
of
warranty
or
any
other
duty
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
war-
with
respect
to
the quality
of
any goods,
the exclusive
remedies
ranty
is
made
by
Miller
with
respect
to
engines,
trade
ac- therefore
shall
be,
at
Miller’s
option
Ill
repair
or
121
replacement
cessories
or
other
items
manufactured
by
others.
Such
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(31
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
the
warranties
of their
respective
manufacturers,
if any . All
Miller
service
station
or
141
payment
of
or
credit
for
the purchase
engines
are
warranted
by
their
manufacturer
for
one
year
from
price Iless
reasonable
depreciation
based
upon
actual
usel
upon
date
of
original
purchase.
return
of
the
goods
at
Customer’s
risk
and
expense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
clal-
f~’
•
Except
as
specified
below,
Miller’s warranty
does
not
apply
mant
on
the
warranty
claim
procedures
to
be
followed.
to
components
having normal
useful
life
of
less
than
one
Ill
year, such
as
spot
welder
tips,
relay
and
contactor
points,
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
MILLERMATIC
parts
that
come
in
contact with
the
welding
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
•
wire including
nozzles
and
nozzle
insulators
where
failure
does
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
not
result
from
defect
in
workmanship
or
material.
BREACH
OF
CONTRACT WHICH,
BUT
FOR
THIS PROVISION,
~
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
Miller
shall
be
required
to
honor
warranty
claims
on war-
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ranted Equipment
in
the
event offailure
resulting
from
a
defect ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
~ within
the
following
periods
from
the
date
of
delivery
of
Equip-
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ment to
the
original
user: ANY
AND
ALL
EOUIPMENT FURNISHED
BY
MILLER
IS
EX-
CLUDED
AND
DISCLAIMED
BY MILLER.
1.
welders,
power
sources
and
components
. .
1
year
2.
Arc
riginal
main
power
rectifiers
3
years
EXCEPT
AS
EXPRESSLY
PROVIDED BY
MILLER
IN
(labor
-
1
year
onlyl
WRITING,
MILLER PRODUCTS
ARE
INTENDED
FOR
weldin
guns
and
feeder/guns
90
days
ULTIMATE
PURCHASE
BY
COMMERCIALiINDUSTRIAL
II
other
Millermatic
Feeders
1
year
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
3.AII
g
II
eplacement
or
repair
parts,
exclusive
of
labor
. 60
days
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
-~
atteries
6
months
WELDING
EOUIPMENT
AND NOT
FOR
CONSUMERS
OR
~s
~provide
CONSUMER
USE.
MILLER’
WARRANTIES
DO
NOT
EXTEND
d that
Miller
is
notified
in
writing within thirty
1301
days
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
of
the
date
of
such
failure.
MILLER’S
WARRANTIES
TO,
ANY
CONSUMER.
S
SECTION
1
-
INTRODUCTION
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented in this
manual and on
various
labels,
tags,
and
plates
provided
on
the
unit
pertain
to
equipment
design,
installation,
operation, maintenance,
and
troubleshooting which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equip-
ment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal safety
and
the
safety
of
others. Therefore, this equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance
with
this
manual and
all
ap
-
plicable codes
such
as,
but
not limited
to,
those
listed
at
the
end
of Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source in
the
welding
power
source
Owner’s
Manual.
Safety
instructions
specifically
pertaining
to
this
unit
ap
-
pear
throughout
this
manual
highlighted
by
the
signal
word
WARNING,
statements
include
installation,
operating,
and
maintenance
procedures
or
practices
which
if
not
carefully followed
could result
in
serious
personal
injury
or
loss
of
life.
An
additional
signal
word,
j~J~~jj
highlights
instructions which
need
special emphasis
to
obtain
the
most
efficient
operation of
this
equipment.
1-2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip-
ment,
it
is
essential
that
Model
Description
and
Serial
(or
Style)
Number
of
the
equipment
be
supplied.
1-3. DESCRIPTION
-
This
unit
is
a
multiple
schedule
control
designed
to
interface
with
a
digital
wire
feeder,
associated
digital voltage control,
and
constant
poten-
tial
welding
power
source.
Each
schedule
can
be
pre-set
before
welding
begins
by
depressing
the
PRESS
TO
SET
button
and
adjusting
the
correponding VOLTAGE
and
WIRE
FEED
controls.
The
preset
values
is
displayed
on
the
DVC
unit
and
wire
feeder
digital
meters
while
the
PRESS
TO
SET
button
is
held
down,
while
welding,
selection
of
a
schedule is
made
by
an
appropriate
external
contact
closure.
SECTION
2
-
INSTALLATION
2-1.
LOCATION
-
The location
should allow room
to
open
front
for
installation,
maintenance,
and
repair.
Lead
lengths
must
be
considered
when
locating
unit.
Mounting
holes
are
provided
for
mounting
the
unit.
The
service
life
and
efficiency
of
the
system
are
reduced
when
it
is
subjected
to
high
levels
of
dust,
dirt,
moisture,
corrosive vapors,
and
extreme
heat.
2-2.
SCHEDULE CONTROL
CONNECTIONS
-
Ex-
ternal
controls
are
required
to
switch
from
one
weld
schedule
(wire
feed
speed and
voltage)
to
another.
Con-
nections
must
be
made
to
terminal
strip
2T.
Route
schedule
control
cables
through
cable
clamps
on
bot
-
tom of
unit.
To
initiate
schedule
1
(schedule
1
controls
are
the
left
most
controls),
a
closure
must
be
made
between
ter
-
minals
217
and
2T4.
To
initiate
schedule
2,
a
closure
must
be
made
between
terminals 2T8
and
2T4; schedule
3
requires
a
closure
between
2T9
and
2T4; schedule
4
requires
a
closure
between 2T10
and
2T4;
and
schedule
5
requires
a
closure
between
2T1
1
and
2T4.
When
none
of
these
schedules
are
energized,
the
weld
parameters
are
determined
by
the
settings
on
the
DVC
unit
and
wire
feeder.
2-3.
AUXILIARY
RELAY
CONNECTION
-
Three
relays
are
provided
for
controlling
auxiliary
equipment.
A set
of
normally-open
and
a
set
of
normally-closed
contacts
are
available
on each
relay.
Connections
must
be
made
to
terminal
strip
3T
(see
circuit
diagram).
Route
leads
through
cable
clamp
on
bottom
of
unit.
To
energize
relays,
a
switch
closure
must
be
made
bet
-
ween
2T4
and
3T12
for
CR14,
3T13
for
CR15,
and/or
3T14
for
CR16.
2-4.
TRIGGER CONTROL
CONNECTIONS
-
A
relay
is
provided
that,
when
energized,
acts
as
the
gun
trigger.
Route
leads
through
cable
clamp
on
bottom
of
unit.
Make
trigger
control
connections
between
1
Ti
and
1T2.
To
energize
relay,
a
switch
closure
must
be
made
bet
-
ween
2T4
and
3T10.
2-5.
GAS
(AND
WATER)
CONTROL
CONNEC
-
TIONS
-
A
relay
is
provided
that
can
be
used
to
energize
the
gas (and
water)
valve(s).
OM-866
Page
1
To
energize
relay,
a
switch
closure
must
be
made
bet
-
ween
2T4 and
3T1
1.
2-6.
INTERCONNECTIONS
WARNING:
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch
live
electrical
parts.
•
Shut
down
welding power
source
and
be
sure
it
cannot
be
accidentally energized
while
making
connections.
1.
Connect
the
plug
labeled
VOLTS
to
the Remote
Control
receptacle
on
the
DVC
unit.
2.
Connect
the
plug
labeled
WIRE
FEED
to
the
Remote
Control
receptacle
on
the
wire
feeder.
3.
Connect
the
two
pole plug
to
the
TRIGGER
receptacle
on
the
wire
feeder.
4.
Remove
the
six
prong
gas
control
plug
from
the
rear
of
the
wire
feeder
and
connect
the
plug
to
the
six
pole
receptacle
that
comes
from
the
multiple
schedule
control.
5.
Connect
the
six
prong
plug
from
the
multiple
schedule
control
to
the
six
pole
gas
control
receptacle
on
the
rear
of
the
wire
feeder.
6.
Connect
the
four
pole
plug
to
the
115
Volts/Connector
Control
receptacle
on
the
DVC
unit.
7.
Connect
four
pole plug
from
the
115
Volts/Con-
tactor
Control
cable
(supplied
with
wire
feeder)
to
the
receptacle
on
the
bottom
of
the
unit.
Con-
nect
the
two
pole
twistlock
plug
to
the
Contactor
Control
receptacle
on
the
welding
power
source.
Connect
the
three
pole
twistlock
plug
to
the
115
VOLTS
AC
receptacle
on
the
welding
power
source.
TA-082 236
SECTION
3
-
OPERATION
3-1.
PRESS
TO
SET
BUTTON
(Figure
3-1)
-
The
PRESS
TO
SET
button
must
be
depressed
when setting
either
the
voltage or
wire
speed
for
the
desired
schedule.
When
this
button
is
depressed
the
load
voltage
setting
displayed
on
the
digital voltage
control
is
the
load
voltage
set
by
the
VOLTAGE
control
on
this
unit.
Likewise,
the
rate
of
wire
feed
displayed
on
the
digital
wire
feeder
is
the
rate of
wire
feed set
by
the
WIRE
SPEED
control
on
this
unit.
Page
2
3-2.
VOLTAGE
CONTROL
(Figure
3-1)
-
A
ten-turn
VOLTAGE
control
provides
a
means
of
determining
out
-
put
load
voltage
for
each
schedule.
Rotating
the
VOLTAGE control
in
a
clockwise
direction
increases
the
output
load
voltage.
3-3.
WIRE
SPEED
CONTROL
(Figure
3-1)
-
A
ten-
turn
WIRE
SPEED
control
provides
a
means
of
deter
-
mining
the
rate
at which welding
wire
will
be
fed
into
Front
View
115
Volts/Contactor
control Cord
Digital
Voltage
Cable
I
-Voltage
ControlCord
wire
Speed
Control
Cord
115
Volts AC Cord
Control
Cords
*Current
Relay
Connection
- DVC
MP-1
Models Only
Figure
2-1.
Interconnections
the
weld
for
each
schedule.
Rotating
the
WIRE
SPEED
control in
a
clockwise
direction
increases
the
rate of
wire
feed.
3-4.
PILOT
LIGHT
(Figure
3-1)
-
The
pilot
lights
in
-
dicate
which
schedule is
energized.
Schedule5
Wire
Speed Control
~
Press
To Set
Button
SECTION
4
-
SEQUENCE
OF
OPERATION
SPARKS,
AND
HOT
and
skin;
NOISE
can
damage
hearing.
•
Wear
correct
eye,
ear,
and bodyprotection.
FUMES
AND
GASES
can
seriously
harm
your
health.
•
Use
enough
ventilation
to
keep
fumes
and
gases
from
the
breathing
zone.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Sources
in
welding
power
source
Owner’s
Manual
for
basic
welding
safety
information.
1.
Make any
necessary
internal
connections.
See
Sections
2-3
through 2-5.
2.
Make
all
interconnections.
See
Section 2-6.
3.
Energize
equipment.
4.
Set
voltage
and
wire
feed
on
the
DVC
unit
and
wire
feeder.
5.
Set
the
five
schedules
(wire
feed speed
and
voltage)
on
the
multiple
schedule
control.
6.
Commence
welding.
Only
one
schedule
can
be
used
at
a
time.
Schedule
1
(
VIII.
ISIF~FI1
AL
IN
G~IWater
A~
Al
IT
TA
nvr
I
— I
WARNING:
Figure
3-1.
Front Panel
View
ARC
RAYS,
SURFACES
can
burn
eyes
OM-866
Page
3
7.
Remove
load,
allow
a
cooling
period,
and
shut
equipment
off
when
not
welding.
HIGH
CONCENTRATION
OF
SHIELDING
GASES
can
seriously
harm health
or
kill.
•
Shut
off
gas
supply at
source
when
not
in
use.
SECTION
5
-
MAINTENANCE
&
TROUBLESHOOTING
ELECTRIC
SHOCK
can
kill.
•
Do
not
touch
ilve
electrical
parts.
•
Disconnect unit from
input
power
before
internal
-
iy
inspecting
or
servicing.
Troubleshooting
of
internal
parts
to
be
performed
only
by
qualified
persons.
5-1.
INSPECTION
AND
UPKEEP
IMPORTANT:
Periodically
inspect the
labels
on
this
unit
for
legibility.
All
labels
must
be
maintained in
a
clearly
readable
state and
replaced
where
necessary.
See
the
Parts
List
for
part
number
of
labels.
Periodically
inspect
all
interconnecting
cords
for
damagbe
to or
breaks
in
the insulating
jacket,
particular
-
ly
at
the plug.
Repair
or
replace
the
cord(s)
as
necessary.
5-2.
FUSE
PROTECTION
-
This
unit
is
protected
by
fuses
Fl
and
F2.
If one
or
both
fuses
should
open,
the
wire
feed
motor would
stop
and
operation
would
cease.
Voltage
and
wire
feed speed revert
to
the
settings
on
the
digital voltage
control
and
wire
feeder.
5-3.
TROUBLESHOOTING
-
It
is assumed
that
pro
-
per
installation
has
been
made,
according to Section
2
of
this
manual,
and
that
the
unit
has
been
functioning
properly until
this
trouble
developed.
Ensure
that
all
connections
on
all
equipment
are
secure
and
that
all
switches
are
in
the proper
position
for
the
welding application.
If
the
unit
still does not
function
check
control
relays and replace
if
necessary.
Ensure
that
all
associated
equipment
is
functioning
pro
-
perly.
If
the
trouble
is
not remedied
after
performing these
procedures,
the
nearest
Factory
Authorized
Service
Station should
be
contacted.
1T3
WIRE
FEED
CONTROLS
1T4 [~j1r~T~L is
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AC
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IN 1113
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ACI
DTI3I.IA
PIGS
Circuit
Diagram
No.
B-070
858-A
Figure
5-1.
Circuit
Diagram
Page
4
May
1981
FORM:
OM-866A
MODEL
MIC-2
PARTS
LIST
7
19
Figure
A
-
Complete Assembly
fix
21.
20
-6
—7
OM-866
Page
1
CR
13-16
D1-1
1
F1,2
Item
Dia.
No.
Mkgs.
Figure
A
1
Ri-b
603856
024
366
010
929
2
Ti
036
135
3
SRi
035914
4
+tSpecial
047
497
tSpecial
5
052 964
6
026 202
7
012633
8
012571
9 1T-3T
038 856
10
PLG4
048842
11
079
531
12
PLG6
048284
079
534
13
RCPT1
048283
079 535
14
010610
15
PLG5
056265
16
PLG3
048379
079 534
17
039828
18
PLG1,2
053075
19
CR1-12
027810
tSpecial
027
811
048 029
079 844
20 PB1-5
079723
079 725
21 Li-S
048
573
007
826
604 525
600 343
600 343
010
311
Part
No.
Description
Complete
Assembly
POTENTIOMETER,
WW
10
turn
2
watt
10K
ohm
KNOB,
pointer
WASHER,
flat
-
spring
3/8
TRANSFORMER,
control
115-24
volts
ac
RECTIFIER,
integrated
30
amp
400
volts
ENCLOSURE
LABEL,
general
precautionary
SUB PANEL
RELAY,
enclosed
24
volts dc
DPDT flanged
DIODE,
rectifier
1
amp
400
volts
straight polarity
FUSE,
miniature
glass
1
amp
HOLDER,
fuse
-
miniature
1/4
x
1-1/4
clip
BLOCK,
terminal
20
amp
14
pole
CONNECTOR,
female
6
socket
w/cable
clamps
CLAMP,
cable
HOUSING
PLUG
&
SOCKETS
(consisting
of)
TERMINAL,
female
1
socket
RECEPTACLE
W/PINS
(consisting
of)
TERMINAL,
male
1
pin
CONNECTOR,
clamp
-
cable
1/2
inch
CONNECTOR,
male
6
contact
10
amp
HOUSING
PLUG
&
SOCKETS
(consisting
of)
TERMINAL,
female
1
socket
CLAMP,
cable
PLUG,
4
pin
MS-3106A-145-2P
RELAY,
enclosed
24
volts
dc
4PDT
BRACKET,
relay
CONNECTOR,
14
pin
CLIP,
retaining
-
socket
relay
SPRING,
holddown
-
relay
SWITCH,
push
button
MC
SPDT
6
amp
125
volts
ac
GUARD,
switch
LIGHT,
indicator
-
red
lens
28
volts
CORD,
No.
183/c
CORD,
No.
182/c
CORD,
No.
165/c
CORD,
No.
165/c
CLAMP,3/4x1/2hole
+
When
ordering
a
component
on
mall
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
tBE
SURE
TO
PROVIDE NO.
5685 WHEN
ORDERING
REPLACEMENT
PARTS.
IT
IS
VERY
IMPORTANT
TO
HAVE
THE
NSPR
NUMBER.
Quantity
10
10
10
1
1
1
1
1
4
11
2
2
3
1
2
1
4
4
6
4
2
2
12
12
12
12
5
5
5
12
ft
4
ft
4
ft
1
5
ft
1
OM-866
Page
2
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